Forming Quality and Defects of Sn-Ag-Cu Alloy by Selective Laser Melting in Air Environment

Zijian Huang; Yang Li; Yongqiang Yang; Yilong Zhang

doi:10.3788/LOP241094

Laser & Optoelectronics Progress, Volume. 62, Issue 3, 0314003(2025)

Forming Quality and Defects of Sn-Ag-Cu Alloy by Selective Laser Melting in Air Environment

Zijian Huang, Yang Li, Yongqiang Yang^*, and Yilong Zhang

School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou 510640, Guangdong , China

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Figures & Tables(22)

Fig. 1. Sn-3.0Ag-0.5Cu powder morphology and size distribution. (a) Powder morphology; (b) size distribution

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Fig. 2. Schematic of scanning strategy and tensile sample. (a) Scanning strategy; (b) tensile sample

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Fig. 3. Sn-3.0Ag-0.5Cu forming samples

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Fig. 4. Changes in density and various factors

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Fig. 5. Energy density- density relationship of forming samples

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Fig. 6. Top-surface morphologies at different process parameters. (a) 20 W-1000 mm/s-0.09 mm; (b) 20 W-800 mm/s-0.07 mm; (c) 30 W-600 mm/s-0.07 mm; (d) 35 W-900 mm/s-0.06 mm; (e) 40 W-900 mm/s-0.07 mm; (f) 40 W-700 mm/s-0.05 mm

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Fig. 7. Microscope morphologies at different process parameters. (a) 20 W-1000 mm/s-0.09 mm; (b) 20 W-800 mm/s-0.07 mm; (c) 30 W-600 mm/s-0.07 mm; (d) 35 W-900 mm/s-0.06 mm; (e) 40 W-900 mm/s-0.07 mm; (f) 40 W-700 mm/s-0.05 mm

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Fig. 8. Tensile properties at different powers. (a) Stress-strain curves; (b) tensile strength and elongation

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Fig. 9. Fracture morphologies at different Laser powers. (a) 25 W; (b) 30 W; (c) 35 W; (d) 40 W

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Fig. 10. Surface and internal morphology of samples in different environments. (a) Surface morphology with protective atmosphere; (b) surface morphology without protective atmosphere; (c) internal morphology with protective atmosphere; (d) internal morphology without protective atmosphere

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Fig. 11. XRD patterns of samples in different environments

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Fig. 12. SEM images of samples in different environments. (a) With protective atmosphere; (b) without protective atmosphere

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Fig. 13. EDS images of samples in different environments. (a) With protective atmosphere; (b) without protective atmosphere

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Fig. 14. Mechanism of spatter generation

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Fig. 15. Spatter generation and residue during the forming process. (a) Spatter generation; (b) spatter residue after paving

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Fig. 16. SEM image of top surface of sample in air atmosphere

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Fig. 17. Influence of spatter on forming and paving. (a) Paving of the first layer; (b) residue of spatter; (c) non-fusion powder caused by spatter; (d) spatter effects on paving roller

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Table 1. Chemical composition of Sn-3.0Ag-0.5Cu powder
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Table 1. Chemical composition of Sn-3.0Ag-0.5Cu powder
Component Sn Ag Cu Sb In Pb Bi
Mass fraction /% Bal. 2.9817 0.4856 0.0111 0.0063 0.0057 0.0026

Table 2. Factor level table
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Table 2. Factor level table
Factor Laser powerP /W Scanning speedV /（mm/s） Hatch spacingS /mm
1 20 600 0.05
2 25 700 0.06
3 30 800 0.07
4 35 900 0.08
5 40 1000 0.09

Table 3. Density test results

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Table 3. Density test results

Number	P /W	V /（mm/s）	S /mm	Relative density /%
1	20	600	0.05	90.40
2	20	700	0.06	92.48
3	20	800	0.07	86.77
4	20	900	0.08	81.21
5	20	1000	0.09	78.60
6	25	600	0.06	94.96
7	25	700	0.07	91.59
8	25	800	0.08	91.88
9	25	900	0.09	93.29
10	25	1000	0.05	93.50
11	30	600	0.07	92.53
12	30	700	0.08	94.37
13	30	800	0.09	92.69
14	30	900	0.05	95.85
15	30	1000	0.06	93.37
16	35	600	0.08	97.15
17	35	700	0.09	96.28
18	35	800	0.05	96.77
19	35	900	0.06	96.24
20	35	1000	0.07	96.46
21	40	600	0.09	96.95
22	40	700	0.05	97.94
23	40	800	0.06	97.79
24	40	900	0.07	97.02
25	40	1000	0.08	97.15

Table 4. Range analysis result of density
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Table 4. Range analysis result of density
Factor A （P） B （V） C （S）
${\bar{K}}_{1 Y}$ 85.89 94.40 94.89
${\bar{K}}_{2 Y}$ 93.04 94.53 94.97
${\bar{K}}_{3 Y}$ 93.76 93.18 92.87
${\bar{K}}_{4 Y}$ 96.58 92.72 92.35
${\bar{K}}_{5 Y}$ 97.37 91.82 91.56
Range $R_{Y}$ 11.48 2.72 3.41
Optimal level A₅ B₂ C₂
Order 1 3 2

Table 5. Density and mechanical properties of samples in different environments
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Table 5. Density and mechanical properties of samples in different environments
Atmosphere Density /% Tensile strength /MPa Elongation /%
Ar 99.12±0.04 88.54±1.59 8.07±0.60
Air 97.02±0.73 87.78±2.91 4.50±0.30

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Zijian Huang, Yang Li, Yongqiang Yang, Yilong Zhang. Forming Quality and Defects of Sn-Ag-Cu Alloy by Selective Laser Melting in Air Environment[J]. Laser & Optoelectronics Progress, 2025, 62(3): 0314003

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